Modular LNG process

ABSTRACT

Disclosed are methods for efficiently and economically designing, constructing, or operating a light hydrocarbon gas liquefaction process for the liquefaction of selected quantities of light hydrocarbon gas. The method includes a light hydrocarbon gas liquefaction launch train to liquefy an initial amount of light hydrocarbon gas and one or more optional subsequent modular expansion phases to said light hydrocarbon gas liquefaction train to liquefy additional selected quantities of light hydrocarbon gas up to a selected maximum quantity of light hydrocarbon gas for the process. The methods employ shared use facilities, such as light hydrocarbon feed gas pretreatment facilities, refrigerant compression facilities, cryogenic heat exchange facilities, access services, other liquefaction equipment, and liquefied product storage and shipping facilities. The use of such shared use facilities allows for subsequent expansion phases or modules to be constructed to increase overall plant capacity, which can reduce the capital costs and space needed relative to prior methods for the design, construction, or operation of a light hydrocarbon liquefaction process which call for construction of a complete liquefaction train and all of its associated components and related equipment.

RELATED APPLICATIONS

This application is entitled to and hereby claims the benefit ofprovisional application Ser. No. 60/414,806 filed Sep. 30, 2002, theteachings of which are incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

This invention relates to a method for liquefying variable selectedquantities of light hydrocarbon gas to produce liquefied lighthydrocarbon gas using plant facilities that comprise an initial lighthydrocarbon gas liquefaction launch train with common shared facilities,which may be expanded by adding plant equipment associated with one ormore optional expansion phases to the launch train.

BACKGROUND OF THE INVENTION

Many light hydrocarbon gas reserves are found in areas of the world thatare remote to any markets for the light hydrocarbon gas. Such lighthydrocarbon gas is referred to as natural gas. This natural gas maycontain condensates that are light gasoline boiling range materials aswell as C₃-C₅ gaseous hydrocarbons and methane.

Frequently such natural gas also contains undesirably high quantities ofwater, acid gas compounds such as sulfur compounds, carbon dioxide andthe like for liquefaction to produce liquefied light hydrocarbon gases,which typically comprise primarily methane and which are frequentlyreferred to as liquefied natural gas (LNG).

When such gases are liquefied, the capacity of the liquefaction plant isdetermined primarily by the available market for the gas, theavailability of transportation to the market and the like. Accordinglyin many instances it is desirable to increase the capacity of theliquefaction process in incremental stages as the market expands toremain in balance with the available market. Accordingly lighthydrocarbon gas liquefaction processes, referred to herein as naturalgas liquefaction processes or LNG processes, are typically installed intrains. The term “train” as used herein refers to a series of vesselscapable of, pre-treating and liquefying natural gas. The gas isdesirably treated to remove acid gases and water to very low levelsprior to charging it to the liquefaction zone. The train also includescompression facilities for compressing the refrigerant required for therefrigeration vessel and the like. The train is an integrated processfor producing a selected quantity of liquefied natural gas. Previously,industry has expanded plant capacity by adding one or more additionaltrains (each of which includes its own gas pretreatment equipment,liquefaction equipment, as well as liquefied product transport andstorage facilities), as required to meet the available market demand andthe like. Such trains have been previously designed to produce a certainquantity of liquefied product with no future expansion of the trainhaving been considered in the design.

In FIG. 1, an embodiment of a light hydrocarbon gas liquefaction systemand process (train) is schematically shown. The system and process, asshown, includes a refrigeration cryogenic heat exchanger 15. As shown,compressed refrigerant is supplied to cryogenic heat exchanger 15 byturbines 31, 33, 35, and 37, which are shaft coupled to refrigerantcompressors 32, 34, 36, and 38, respectfully. High-pressure refrigerantis supplied to compressors 32 and 34 by high-pressure refrigerant lines61 and 62. These lines typically return high-pressure refrigerant fromcryogenic heat exchanger 15 after it has served its purpose as arefrigerant and has been warmed to a substantially gaseous condition.Compressed high-pressure refrigerant is supplied to cryogenic heatexchanger 15 via lines 63 and 64. Low-pressure refrigerant is suppliedto compressors 36 and 38 by low-pressure refrigerant lines 65 and 66.These lines typically return low-pressure refrigerant from cryogenicheat exchanger 15 after it has served its purpose as a refrigerant andhas been warmed to substantially gaseous condition. Compressedlow-pressure refrigerant is supplied to cryogenic heat exchanger 15 vialines 67 and 68. No significance should be attributed to this exceptthat refrigerants can be produced from compressors 32, 34, 36, and 38 atdifferent pressures if desired and passed to cryogenic heat exchanger 15at different points in the refrigeration process if desired. The same ordifferent refrigerants can be used in the high-pressure and low-pressurerefrigerant loops, as known to those skilled in the art.

Further, an inlet light hydrocarbon gas that has desirably been treatedto remove acid gases and water is charged to cryogenic heat exchanger 15via line 59. The liquefied light hydrocarbon gas product is producedthrough line 69. Typically, a natural gas or other light hydrocarbon gasstream is introduced to acid gas removal vessel 10 via line 40. Acid gasregenerator 11 is shown in fluid communication with acid gas removalvessel 10 via lines 41 and 42. The treated gas is typically recoveredfrom vessel 10 through line 43. The recovered gases are passed via lines44, 45, and 46 to designated dehydration vessels 20, 21, and 22.Typically vessel 10 is an aqueous amine scrubber, operating as known tothose skilled in the art. The aqueous amine may be selected frommaterials such as digycolanolamine (DGA), diethylamine (DEA),methyldiethanolamine (MDEA), methylethylanolamine (MEA), SULFINOL(trademark of Shell Oil Company), activated methyldiethanolamine(aMDEA), and combinations thereof. Carbon dioxide is typically removedto levels less than about 60 parts per million (ppm) while sulfur istypically removed to levels less than about 4 ppm through vessels suchas acid gas removal vessel 10.

The general operation of such acid gas removal vessels, as shown, iswell known to those skilled in the art. Since each train has beentypically constructed separately as market demands require, it is commonto provide an acid gas removal vessel and an associated acid gasregenerator for each train. This has also been the case for othercomponents of such trains and associated infrastructure.

Since the aqueous amine process produces a gas that is relativelysaturated in water and since the water freezes at a temperature muchhigher than methane, which constitutes the majority of the natural gasstream to be liquefied, it is necessary that at least a major portion ofthe water be removed from the gas stream. Treated water-saturated gas isrecovered from acid gas removal vessel 10 via line 43 where it is passedto dehydration vessels 20, 21, and 22 via lines 44, 45, and 46,respectfully. Water is selectively removed through dehydration vessels20, 21, and 22 to produce a dewatered gas in lines 54, 55, and 56. Thedehydrated gas from vessels 20, 21, and 22 is then combined and passedto cryogenic heat exchanger 15 via line 59. Typically, these dehydrationvessels contain an adsorption material such as a molecular sieve,activated alumina, or the like. Such material is effective in removingthe water from an inlet gaseous stream to extremely low levels, thusrendering the gaseous stream suitable for liquefaction in cryogenic heatexchanger 15. Typically three vessels are placed in each train to meetthe requirements to dehydrate incoming gas. The process may also useadsorption materials for removal of other contaminants, such as mercury.

In the use of dehydration vessels 20, 21, and 22, two vessels willgenerally serve to remove the water from its associated feed gas stream,44, 45, or 46, while one vessel is being regenerated by hot regenerationgas. Such configuration is depicted in FIG. 1 where dehydration vessels20 and 21 serve to produce relatively water free gas streams 54 and 55by removing water from inlet gas streams 44 and 45. Dehydration vessel22, in the depicted configuration, is being regenerated by hotregeneration gas where the regeneration gas enters the vessel via line70 and exits via line 71. All dehydration vessels 20, 21, and 22 allhave the capability to operate in either dehydration or regenerationmode (though not shown for simplicity), as indicated in FIG. 1 by vessel22 and process streams 70 and 71. Typically three vessels are placed ineach train to meet the requirements of dehydration the incoming gas.

The acid gas removal vessels are readily regenerated as well known tothose skilled in the art by a variety of techniques. One commonly usedtechnique is the use of a reboiler on vessel 11 for regeneration.

A wide variety of refrigeration processes are contemplated within thescope of the present invention. No novelty is claimed with respect tothe particular type of refrigeration process or vessel used. The processof the present invention is considered to be useful with any type ofliquefaction process that requires light hydrocarbon gas as an inletstream.

Clearly, the construction of separate trains of refrigeration processesas discussed above results in the expenditure of considerable capital toduplicate common facilities in each train, such as the dehydrationvessels, acid gas removal vessels, and refrigerant compression andcryogenic liquefaction equipment. Accordingly, a continuing search hasbeen directed to the development of systems and methods for reducing theunnecessary expense for these duplicate vessels.

SUMMARY OF THE INVENTION

According to the present invention, it has now been found that theexpense required for these vessels can be reduced by a method fordesigning an efficient and economical light hydrocarbon gas liquefactionprocess for the liquefaction of selected quantities of light hydrocarbongas in an initial launch light hydrocarbon gas liquefaction train andone or more optional subsequent expansion phases to said lighthydrocarbon liquefaction train to liquefy additional selected quantitiesof light hydrocarbon gas up to a selected maximum quantity of lighthydrocarbon gas for the process. The method comprises:

a) designing the light hydrocarbon gas liquefaction launch train for theliquefaction of the selected initial quantity of light hydrocarbon gas,the launch train including facilities for light hydrocarbon gaspretreatment to remove acid gases and water, refrigerant compression,cryogenic heat exchange, access services, light hydrocarbon gasliquefaction, and liquefied light hydrocarbon gas product storage andshipping;

b) designing at least a portion of the facilities in the launch trainfor shared use by the launch train and any subsequent optional modularexpansion phases to said launch train; and

c) designing at least a portion of the launch train facilities forshared use by modular expansion, as required by the addition of one ormore subsequent optional expansion phases to the launch train, up to themaximum capacity as required to liquefy the selected maximum quantity oflight hydrocarbon gas for the process, the shared use facilities of thelaunch train being designed at a size sufficient to liquefy the selectedmaximum quantity of light hydrocarbon gas for the process either in thelaunch train as constructed or as constructed in the launch train andexpanded in the one or more optional expansion phases to the requiredcapacity.

It has further been found that an improvement is achieved by a methodfor efficiently and economically constructing a light hydrocarbon gasliquefaction process for the liquefaction of selected quantities oflight hydrocarbon gas in an initial light hydrocarbon gas liquefactionlaunch train and one or more optional subsequent expansion phases tosaid light hydrocarbon liquefaction train to liquefy additional selectedquantities of light hydrocarbon gas up to a selected maximum quantity oflight hydrocarbon gas for the process. The method comprises:

a) constructing a light hydrocarbon gas liquefaction launch train forthe liquefaction of a first selected quantity of light hydrocarbon gasincluding facilities for light hydrocarbon gas pretreatment to removeacid gases and water, refrigerant compression, cryogenic heat exchange,access services, light hydrocarbon gas liquefaction, and liquefied lighthydrocarbon gas product storage and shipping;

b) positioning at least a portion of the facilities in the launch trainfor shared use by the launch train and optional subsequent expansionphases;

c) constructing at least a portion of the launch train facilities forshared use for modular expansion as required by the addition ofsubsequent expansion phases up to the maximum capacity required toliquefy the maximum quantity of light hydrocarbon gas or initiallyconstructing the portion of the launch train facilities for shared useof a size sufficient to liquefy the maximum quantity of liquefied lighthydrocarbon gas for the process either in the launch train asconstructed or as constructed in the launch train and expanded in theone or more optional expansion phases to the required capacity.

It has also been found that an improvement is achieved by a method forefficiently and economically operating a light hydrocarbon gasliquefaction process for the liquefaction of selected quantities oflight hydrocarbon gas. The process includes a light hydrocarbon gasliquefaction launch train to liquefy an initial amount of lighthydrocarbon gas and one or more optional subsequent expansion phases tosaid light hydrocarbon gas liquefaction train to liquefy additionalselected quantities of light hydrocarbon gas up to a selected maximumquantity of light hydrocarbon gas for the process. The method comprises:

a) constructing the light hydrocarbon gas liquefaction launch train forthe liquefaction of the selected initial quantity of light hydrocarbongas, the launch train including facilities for light hydrocarbon gaspretreatment to remove acid gases and water, refrigerant compression,cryogenic heat exchange, access services, light hydrocarbon gasliquefaction, and liquefied light hydrocarbon gas product storage andshipping;

b) positioning at least a portion of the facilities in the launch trainfor shared use by the launch train and any subsequent optional modularexpansion phases to said launch train;

c) constructing at least a portion of the launch train facilities forshared use by modular expansion, as required by the addition of one ormore subsequent optional expansion phases to the launch train, up to themaximum capacity as required to liquefy the selected maximum quantity oflight hydrocarbon gas for the process, the shared use facilities of thelaunch train being designed at a size sufficient to liquefy the selectedmaximum quantity of light hydrocarbon gas for the process either in thelaunch train as constructed or as constructed in the launch train andexpanded in the one or more optional expansion phases to the requiredcapacity; and

d) processing light hydrocarbon gas in the launch train to produceliquefied light hydrocarbon gas.

In embodiments, the invention also relates to a method for efficientlyand economically operating a light hydrocarbon gas liquefaction processfor the liquefaction of selected quantities of light hydrocarbon gas.The process includes a light hydrocarbon gas liquefaction launch trainto liquefy an initial amount of light hydrocarbon gas and one or moresubsequent expansion phases to said light hydrocarbon gas liquefactiontrain to liquefy additional selected quantities of light hydrocarbon gasup to a selected maximum quantity of light hydrocarbon gas for theprocess. The method comprises:

a) constructing the light hydrocarbon gas liquefaction launch train forthe liquefaction of the selected initial quantity of light hydrocarbongas, the launch train including facilities for light hydrocarbon gaspretreatment to remove acid gases and water, refrigerant compression,cryogenic heat exchange, access services, light hydrocarbon gasliquefaction, and liquefied light hydrocarbon gas product storage andshipping;

b) positioning at least a portion of the facilities in the launch trainfor shared use by the launch train and subsequent modular expansionphases to said launch train;

c) constructing at least a portion of the launch train facilities forshared use by modular expansion, as required by the addition of one ormore subsequent expansion phases to the launch train, up to the maximumcapacity as required to liquefy the selected maximum quantity of lighthydrocarbon gas for the process, the shared use facilities of the launchtrain being designed at a size sufficient to liquefy the selectedmaximum quantity of light hydrocarbon gas for the process either in thelaunch train as constructed or as constructed in the launch train andexpanded in the one or more expansion phases to the required capacity;

d) processing light hydrocarbon gas in the launch train to produceliquefied light hydrocarbon gas;

e) constructing one or more expansion phases to the launch train toincrease the capacity of the launch train as required to liquefyadditional selected quantities of light hydrocarbon gas up to theselected maximum quantity of light hydrocarbon gas for the process, saidexpansion phases capable of producing liquefied light hydrocarbon gas byuse of the shared use facilities in the launch train as constructed inthe launch train or as constructed in the launch train and expanded inthe one or more expansion phases to the required capacity; and

f) processing light hydrocarbon gas into liquefied light hydrocarbon gasusing the launch train and the one or more expansion phases employingthe shared use facilities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a process for liquefying lighthydrocarbon gas using one liquefaction train.

FIG. 2 is a schematic diagram of an embodiment of the invention using anacid gas removal facility as a shared use facility where a launch traincomprises equipment and associated piping depicted with solid lines andsubsequent expansion phases (modules) to the launch train compriseequipment and associated piping depicted by the dashed lines.

FIG. 3 is a schematic diagram of an embodiment of the invention using adehydration facility as a shared use facility where a launch traincomprises equipment and associated piping depicted with solid lines andsubsequent expansion phases (modules) to the launch train compriseequipment and associated piping depicted by the dashed lines.

FIG. 4 is a schematic diagram of an embodiment of a liquefactionfacility where a launch train comprises refrigerant compression andcryogenic heat exchange equipment and associated piping depicted withsolid lines and subsequent expansion phases (modules) compriserefrigerant compression and cryogenic heat exchange equipment andassociated piping depicted by the dashed lines.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the description of the Figures, numerous pumps, valves and the like,necessary to achieve the flows shown, as known to those skilled in theart, have not been shown for simplicity.

The present invention provides an improved efficiency and economy inoperating a light hydrocarbon gas liquefaction process for theliquefaction of selected quantities of light hydrocarbon gas by use ofan initial light hydrocarbon gas liquefaction launch train, and up to aselected maximum quantity of liquefied light hydrocarbon gas using oneor more subsequent modular expansion phases by a method comprising thedesign of such process to include certain facilities which are common toboth the initial launch train and subsequent expansion phases. Asindicated the term “light hydrocarbon gas liquefaction train” or “train”refers to those units and facilities used for pretreatment andpost-treatment of the gas feeds to the liquefaction facility as well asthe facilities for compressing the refrigerant and the like as shown inFIG. 1. Such acid gas facilities can include acid gas removal equipment,dehydration equipment, mercury or other contaminant removal equipment,and refrigerant compression and cryogenic heat exchange equipment, andassociated piping.

Vessels for the removal of acid gases and for dehydration typicallyinclude both an absorption vessel and a regenerator vessel to regeneratethe media used in the vessel for acid gas removal or for dehydrationrespectively. For example in the acid gas removal section an absorptionvessel and a regeneration vessel are required. If these facilities areduplicated in each train (as previously practiced within the art) theneach train will include an absorption vessel and a regenerator vessel.Clearly an economy could be realized if upon design and construction ofthe initial launch train, the train was designed and constructed toinclude a regenerator for the aqueous amine used in the acid gasabsorption vessels of a size sufficient to accommodate additionalabsorption vessels as required as additional expansions are desired.Desirably this equipment is located in an area which is equallyaccessible or at least accessible to all necessary equipment so thatadditional acid gas removal vessels can be positioned to serve thelaunch train and additional expansions and remain in fluid communicationwith the regenerator vessel for the regeneration and recycling of theaqueous amine solution used for the acid gas absorption. For instance,these vessels could be commonly sited with the gas from which the acidgases have been removed being then passed to the appropriateliquefaction facility. This results in the construction of only a singleaqueous amine regeneration vessel and permits the construction of onlyan additional acid gas absorption vessel for each subsequentliquefaction expansion phase.

Similarly when dehydration vessels are used three are typicallyconstructed for each train. Two vessels are typically used foradsorption of water with the third being regenerated by hot gases whichdrive out the water. When the estimated maximum quantity of gas to beproduced is known, then a plurality of dehydration vessels can be placedtogether at a common site to dewater the reduced acid gas content gasproduced by the removal of the acid gases to produce a dewatered lightliquid hydrocarbon gas stream having a reduced acid gas content. It iswell known that the regeneration times for such vessels is substantiallyless than the time required on line for dehydration. Prior practice hasbeen to provide three dehydration vessels for each train so that twovessels are on line while the other vessel is being regenerated. If thevessels are located at a common site only one extra vessel needs to beadded during an expansion. The single vessel is sufficient since the twovessels which are operative at any given time will operate for longenough to provide time to regenerate the third vessel. When the thirdvessel is regenerated the gas flow from one of the other vessels whichmay have become spent can be rerouted to the regenerated vessel with thevessel which has become spent then being regenerated. By the use of thevessels in this fashion a plurality of vessels can be used without theneed to produce a second vessel for regeneration for each dehydrationvessel. These vessels can be used in groups wherein the number ofvessels usable in a group is equal to a number equal to the run time foreach vessel divided by the regeneration time to produce a number whichis a whole number disregarding any fraction plus one. This numberdefines the number of vessels which can be used with one additionalvessel for regeneration. In the event that the regeneration time isequal to one third of the run time then four vessels can be used toservice three trains rather than the six vessels which would normally beconstructed according to the prior art. Similarly improvements can berealized in the construction of docking facilities, liquid natural gasstorage and shipping facilities, C₃+ hydrocarbon removal facilities andthe like.

According to the present invention these facilities are produced in aform in the first launch train from which they can be expanded bymodular increments or of a size necessary to handle the maximum quantityof light hydrocarbon gas which will be processed through theliquefaction process.

Typically, such processes have been expanded by adding trains and asindicated previously by duplicating all the facilities required for eachtrain in each train. According to the present invention sharedfacilities are used by the first liquefaction launch train and thesubsequent modular expansion phases. The initial launch liquefactiontrain is designed to size the shared equipment of a size capable ofhandling the maximum capacity expected by the combination of the initiallaunch train and incremental expansion as modular expansion phases areadded to increase capacity. For instance, less than a full amount ofcompressed refrigerant may be charged in a subsequent modular expansioninitially. This permits addition of the expansion phase before a marketexists for all of the liquefied natural gas which could be producedthrough the facility. It also permits ready expansion of this systemwhen the market expands to include a full compressed refrigerant chargeto another subsequent modular expansion phase.

FIG. 2 illustrates a phased expansion of an acid gas removal unit (AGRU)where the solid lines represent a launch (new or existing) train and thedotted lines represent optional future expansion equipment andassociated piping required for a one or two-phase expansion. As depictedpreviously in FIG. 1, each train typically contains an acid gas removalvessel 10 and an acid gas regenerator 11. According to the presentinvention, it is desirable that the facilities required for acid gasremoval for the initial launch train and subsequent expansions bearranged in a common area, or at least in reasonable fluid communicationin efforts to reduce capital expenditure and improve the overall plantlayout. For example, if it is desired to increase the plant throughput,acid gas removal vessel 110 and acid gas regenerator 111 along withassociated piping could be installed, thus increasing the throughput ofthe original AGRU. A further train expansion could be obtained throughthe addition of acid gas removal vessel 210 and acid gas regenerator 211along with associated piping. Depending on plant operating conditionsand parameters, the need for multiple acid gas regenerators could beeliminated by using one acid gas regenerator, which would further reducethe capital expenditure and space (real estate) required by full trainexpansions previously known in the art. Though not shown in FIG. 2, anddepending on the amount of acid gas in the light hydrocarbon feed gas,optionally the acid gas regenerator 11 can be sized so that it canhandle all of the regeneration requirements for future expansions,thereby eliminating the need for acid gas regenerators 111 and 211.

After the implementation of the two expansions shown in FIG. 2, threeacid gas removal vessels 10, 110, and 210 are available for use toremove acid gases from inlet gas streams, which are charged via line 40′(forty prime). The inlet gas may be passed via lines 40, 140, and 240 toany or all of the acid gas removal vessels 10, 110, and 210. The acidgas removal vessels shown may employ aqueous amine solutions, as knowngenerally in the art, and operate as discussed in connection withFIG. 1. The gaseous streams having reduced acid gas content arerecovered through lines 43, 143, and 243 where they combine to createstream 43′ (forty-three prime), which then continues through theremainder of the process.

It is desired that a plurality of train expansions be serviced by theacid gas removal facility shown in FIG. 2. As shown, the facility couldattend to the acid gas removal needs for the launch train and additionalexpansions with regeneration occurring in the three regeneration vessels11, 111, and 211, or one appropriately sized regeneration vessel aspreviously mentioned. The fresh amine is produced via lines 42, 142, and242 and passed into the upper portion of vessels 10, 110, and 210,respectfully. The spent amine is passed via lines 41; 141, and 241 tovessels 11, 111, and 211 to complete the loop. If it is desired todesign and operate only one acid gas regeneration vessel, the freshamine from the acid gas regeneration vessel, carried by one primary line(not shown for simplicity) exiting the lower portion of the regenerationvessel, would be appropriately distributed through lines 42, 142, and242. Similarly, the spent amine would leave acid gas removal vessels 10,110, and 210 via lines 41, 141, and 241 and combine into one primaryline (also not shown) entering the upper portion of the single acid gasregeneration vessel. In either embodiment, a regenerated aqueous aminesolution is provided to the upper portion of each vessel on a continuousbasis with spent amine solution being recovered from the lower portionof the vessel and passed back to regeneration.

Should one regeneration vessel be used, the vessel must be sized toprovide sufficient fresh regenerated aqueous amine to remove the acidgas compounds from the gaseous stream charged to the operating acid gasremoval vessels, 10, 110, and 210. The sizing of one regeneration vesselentails little additional expense to provide sufficient regeneratingcapacity to provide sufficient regenerated amine to service all four ofthe vessels. Thus, additional expansions can be made by simply adding asingle acid gas removal contact vessel. So long as significantregeneration capacity exists, the gain in gas throughput is obtained ata considerably reduced capital cost by virtue of requiring only theaddition of a single acid gas removal vessel rather than an acid gasremoval vessel and a regeneration vessel.

In a preferred embodiment shown in FIG. 3, an arrangement of vesselssuitable for use in dehydrating a light hydrocarbon gas stream has beenshown, where solid lines represent a launch (new or existing) train andthe dotted lines represent possible expansion equipment and associatedpiping required for a one or two phase expansion. An inlet gas stream isreceived through line 43′ (forty-three prime) and may be passed todehydration vessels 20, 21, 22, 120, and 220 that are not inregeneration mode via lines 44, 45, 46, 47, and 48 respectfully. Theproduct streams, virtually free of water, are recovered through processlines 54, 55, 56, 57, and 58 respectfully. Each vessel can be designedfor operation in either dehydration or regeneration mode, which has notbeen fully shown for simplicity. For example, as shown in FIG. 3 by thesolid lines, vessels 20 and 21 are in dehydration mode while vessel 22is in regeneration mode where a stripping gas is introduced to vessel 22via line 70 and exits via line 71. Although not depicted in FIG. 3, eachvessel is designed with appropriate valves and piping so that alldehydration vessels may operate in either dehydration or regenerationmode, as illustrated through the previous example.

In the preferred embodiment shown in FIG. 4, an arrangement of cryogenicheat exchangers and associated compressors, turbines, and pipingsuitable for the liquefaction of a light hydrocarbon gas has been shownwhere solid lines represent a launch (new or existing) train and thedotted lines represent possible expansion equipment and associatedpiping required for a one or two phase modular expansion. A gas streamthat has been treated in the AGRU and dehydrated is received by processline 59′ (fifty-nine prime) and may be distributed to cryogenic heatexchangers 15, 115, and 215 via lines 59, 159, and 259 respectfully.

As shown, compressed refrigerant is supplied to cryogenic heatexchangers 15, 115, and 215 by turbines 31, 33, 35, 37, 131, 135, 231,and 235 respectively, which are shaft coupled to refrigerant compressors32, 34, 36, 38, 132, 136, 232, and 236 respectfully. High-pressurerefrigerant is supplied to compressors 32, 34, 132, and 232 byhigh-pressure refrigerant lines 61, 62, 162, and 262. These linestypically return high-pressure refrigerant from cryogenic heatexchangers 15, 115, and 215 after it has served its purpose as arefrigerant and has been warmed to a substantially gaseous condition.Compressed high-pressure refrigerant is supplied to cryogenic heatexchangers 15, 115, and 215 via lines 63, 64, 163, and 263. Low-pressurerefrigerant is supplied to compressors 36, 38, 136, and 236 bylow-pressure refrigerant lines 65, 66, 166, and 266. These linestypically return low-pressure refrigerant from cryogenic heat exchangers15, 115, and 215 after it has served its purpose as a refrigerant andhas been warmed to substantially gaseous condition. Compressedlow-pressure refrigerant is supplied to cryogenic heat exchangers 15,115, and 215 via lines 67, 68, 167, and 267. No significance should beattributed to this except that refrigerants can be produced fromcompressors 32, 34, 36, 38, 132, 136, 232, and 236 at differentpressures if desired and passed to cryogenic heat exchangers 15, 115,215 at different points in the refrigeration process if desired and asappropriate. The same or different refrigerants can be used in thehigh-pressure and low-pressure refrigerant loops.

While not shown on FIG. 4, mercury or other contaminant removalequipment is typically employed in a light hydrocarbon liquefactionprocess. For mercury removal, there are two methods to accomplish thetask, a non-regenerative system or a regenerative system.

In the non-regenerative system, elemental mercury in the gas phase istrapped by mercury trapping material such as sulfur, which fixes thevolatile mercury in the form of non-volatile mercury sulfide (HgS). Mostcommonly, an activated carbon is chemically treated or impregnated witha mercury-fixing compound such as sulfur. The mercury is chemi-sorbedonto the non-regenerative carbon, which must be periodically replaced.

In the regenerative system, elemental mercury in the gas phase istrapped by mercury trapping material such as silver. The silver issupported on alumina or zeolite (mol sieve), or other inert support.This material is placed in the mol sieve unit and the mercury isdesorbed during the regeneration cycle.

According to the present invention, an improved system and method forproducing natural gas for refrigeration process that has been treated byacid gas removal and dehydration comprising a launch train and multiplephased expansions has been shown. It will be readily appreciated bythose skilled in the art, upon review of FIGS. 2 through 4, that savingsin terms of space (real estate) and capital expenditure that can beobtained through modular expansion according to the invention.

According to the present invention improved efficiency and economy havebeen achieved by including in a launch train of a light hydrocarbon gasliquefaction process shared facilities which can be used by subsequentexpansions by either modularization or by use of the shared facilitieswhich are designed for the desired maximum capacity of light hydrocarbongas to be processed in the liquefaction process initially. This resultsin substantial savings in the overall operation of the process atmaximum capacity and provides for great ease in expanding the processincrementally. For instance in the treatment of the light hydrocarbongas streams improved economy can be achieved as discussed by adding aregeneration section which is of a size suitable to regenerate aqueousamine for all of the acid gas removal vessels which are contemplated atmaximum capacity of the process comprising all of the trains incombination. While this capacity may not be achieved for many years theadded cost of the larger vessel is relatively minor compared to thesavings by comparison to the use of a second regeneration vessel and asecond acid gas removal vessel for each train. Similarly the use of thedehydration vessels as discussed above has resulted in substantialsavings. For instance even when only two vessels are used initially theaddition of a third vessel for operation in this fashion permits theaddition of a second train but with the addition of only a singledehydration vessel rather than the pair of dehydration vessels usuallyrequired. Further as noted in FIGS. 2-4 in the event that less than afull liquefaction facility is required for the desired increase incapacity the added liquefaction facility can be added with a reducedlight hydrocarbon gas flow with a reduced quantity of compressedrefrigerant to produce a liquefied light hydrocarbon gas stream in aquantity suitable to meet the current demand. Similarly dockingfacilities, access roads, C₃+ hydrocarbon removal facilities and thelike can all be designed for either modular expansion or of a size toaccommodate the maximum plant size initially with the resultingefficiency in process expansion when required and economies achieved byreducing the duplication of equipment.

While the present invention has been described by reference to certainof its preferred embodiments, it is pointed out that the embodimentsdescribed are illustrative rather than limiting in nature and that manyvariations and modifications are possible within the scope of thepresent invention. Many such variations and modifications may beconsidered obvious and desirable by those skilled in the art based upona review of the foregoing description of preferred embodiments.

1. A light hydrocarbon gas liquefaction process for the liquefaction of selected quantities of light hydrocarbon gas, said process including a light hydrocarbon gas liquefaction launch train to liquefy an initial amount of light hydrocarbon gas and one or more optional subsequent expansion phases to said light hydrocarbon gas liquefaction launch train to liquefy additional selected quantities of light hydrocarbon gas up to a selected maximum quantity of light hydrocarbon gas for the process, the process comprising: a) constructing the light hydrocarbon gas liquefaction launch train for the liquefaction of the initial amount of light hydrocarbon gas, the launch train including facilities for light hydrocarbon gas pretreatment to remove at least one of acid gases, mercury, and water; facilities for refrigerant compression; facilities for cryogenic heat exchange; access services; facilities for light hydrocarbon gas liquefaction; facilities for liquefied light hydrocarbon gas product storage and shipping; and C³ ⁺ hydrocarbon removal facilities; b) positioning at least a portion of the facilities in the launch train for shared use by the launch train and one or more subsequent optional modular expansion phases for liquefaction of up to the selected maximum quantity of light hydrocarbon gas; c) constructing at least a portion of the launch train facilities for shared use by modular expansion, as required by the addition of one or more subsequent optional expansion phases to the launch train, up to a maximum capacity as required to liquefy the selected maximum quantity of light hydrocarbon gas, the shared use facilities of the launch train being designed at a size sufficient to liquefy the selected maximum quantity of light hydrocarbon gas in the launch train as constructed and expanded in the one or more optional expansion phases to the required capacity; and d) processing light hydrocarbon gas in the launch train to produce liquefied light hydrocarbon gas.
 2. The process of claim 1 further comprising the following steps: e) constructing one or more expansion phases to the launch train to increase the capacity of the launch train as required to liquefy additional selected quantities of light hydrocarbon gas up to the selected maximum quantity of light hydrocarbon gas for the process, said expansion phases being capable of producing liquefied light hydrocarbon gas by use of the shared use facilities in the launch train as constructed and expanded in the one or more expansion phases up to the required capacity; and f) processing light hydrocarbon gas into liquefied light hydrocarbon gas using the launch train and the one or more expansion phases employing the shared use facilities.
 3. The process of claim 1 wherein the shared use facilities include acid gas removal equipment.
 4. The process of claim 1 wherein the shared use facilities include mercury removal equipment.
 5. The process of claim 1 wherein the shared use facilities include dehydration equipment.
 6. The process of claim 1 wherein the shared use facilities include refrigerant compression equipment and cryogenic heat exchange equipment.
 7. A light hydrocarbon gas liquefaction process for the liquefaction of selected quantities of light hydrocarbon gas, said process including a light hydrocarbon gas liquefaction launch train to liquefy an initial amount of light hydrocarbon gas and one or more subsequent expansion phases to said hydrocarbon gas liquefaction launch train to liquefy additional selected quantities of light hydrocarbon gas up to a selected maximum quantity of light hydrocarbon gas for the process, the process comprising: a) constructing the light hydrocarbon gas liquefaction launch train for the liquefaction of the initial amount of light hydrocarbon gas, the launch train including facilities for light hydrocarbon gas pretreatment to remove at least one of acid gases, mercury, and water; facilities for refrigerant compression; facilities for cryogenic heat exchange; access services; facilities for light hydrocarbon gas liquefaction; facilities for liquefied light hydrocarbon gas product storage and shipping; and C³ ⁺ hydrocarbon removal facilities: b) positioning and sizing at least a portion of the facilities in the launch train for shared use by the launch train and subsequent modular expansion phases; c) constructing at least a portion of the launch train facilities for shared use by modular expansion, as required by the addition of one or more subsequent expansion phases to the launch train, up to a maximum capacity as required to liquefy the selected maximum quantity of light hydrocarbon gas, the shared use facilities of the launch train being designed at a size sufficient to liquefy the selected maximum quantity of light hydrocarbon gas in the launch train as constructed and expanded in the one or more expansion phases to required capacity; d) processing light hydrocarbon gas in the launch train to produce liquefied light hydrocarbon gas; e) constructing one or more expansion phases to the launch train to increase the capacity of the launch train as required to liquefy additional selected quantities of light hydrocarbon gas up to the selected maximum quantity of light hydrocarbon gas for the process, said expansion phases being capable of producing liquefied light hydrocarbon gas by use of the shared use facilities in the launch train as constructed and expanded in the one or more expansion phases up to the required capacity; and f) processing light hydrocarbon gas into liquefied light hydrocarbon gas using the launch train and the one or more expansion phases employing the shared use facilities.
 8. The process of claim 7 wherein the shared use facilities include acid gas removal facilities.
 9. The process of claim 7 wherein the shared use facilities include mercury removal facilities.
 10. The process of claim 7 wherein the shared use facilities include dehydration facilities.
 11. The process of claim 7 wherein the shared use facilities include refrigerant compression equipment and cryogenic liquefaction facilities.
 12. A method for designing an efficient and economical light hydrocarbon gas liquefaction process for the liquefaction of selected quantities of light hydrocarbon gas in an launch light hydrocarbon gas liquefaction launch train and one or more optional subsequent expansion phases to said light hydrocarbon gas liquefaction launch train to liquefy additional selected quantities of light hydrocarbon gas up to a selected maximum quantity of light hydrocarbon gas for the process, the method comprising: a) designing the light hydrocarbon gas liquefaction launch train for the liquefaction of the selected initial quantity of light hydrocarbon gas, the launch train including facilities for light hydrocarbon gas pretreatment to remove at least one of acid gases, mercury, and water; facilities for refrigerant compression; facilities for cryogenic heat exchange; access services; facilities for light hydrocarbon gas liquefaction; facilities for liquefied light hydrocarbon gas product storage and shipping; and C³ ⁺ hydrocarbon removal facilities; b) designing and sizing at least a portion of the facilities in the launch train for shared use by the launch train and any subsequent optional modular expansion phases to said launch train; and, c) designing and sizing at least a portion of the launch train facilities for shared use by modular expansion, as required by the addition of one or more subsequent optional expansion phases to the launch train, up to a maximum capacity as required to liquefy the selected maximum quantity of light hydrocarbon gas for the process, the shared use facilities of the launch train being designed at a size sufficient to liquefy the selected maximum quantity of light hydrocarbon gas for the process in the launch train as constructed and expanded in the one or more optional expansion phases up to the required capacity.
 13. The method of claim 12 further comprising the following steps: d) designing one or more expansion phases to the launch train to increase the capacity of the launch train as required to liquefy additional selected quantities of light hydrocarbon gas up to the selected maximum quantity of light hydrocarbon gas for the process, said expansion phases capable of producing liquefied light hydrocarbon gas by use of the shared use facilities in the launch train as constructed and expanded in the one or more expansion phases to the required capacity.
 14. The method of claim 12 wherein the shared use facilities include acid gas removal equipment.
 15. The method of claim 12 wherein the shared use facilities include mercury removal equipment.
 16. The method of claim 12 wherein the shared use facilities include dehydration equipment.
 17. The method of claim 12 wherein the shared use facilities include refrigerant compression equipment and cryogenic heat exchange equipment.
 18. A method for efficiently and economically constructing a light hydrocarbon gas liquefaction process for the liquefaction of selected quantities up to a selected maximum quantity of light hydrocarbon gas in an initial light hydrocarbon gas liquefaction launch train and one or more optional subsequent expansion phases to said initial light hydrocarbon gas liquefaction launch train to liquefy additional selected quantities of light hydrocarbon gas up to the selected maximum quantity of light hydrocarbon gas for the process, the method comprising: a) constructing a light hydrocarbon gas liquefaction launch train for the liquefaction of a selected initial quantity of light hydrocarbon gas including facilities for light hydrocarbon gas pretreatment to remove at least one of acid gases, mercury and water; facilities for refrigerant compression; facilities for cryogenic heat exchange; access services; facilities for light hydrocarbon gas liquefaction; facilities for liquefied light hydrocarbon gas product storage and shipping; and C³ ⁺ hydrocarbon removal facilities: b) positioning at least a portion of the facilities in the launch train for shared use by the launch train and optional subsequent expansion phases; c) constructing and sizing at least a portion of the launch train facilities for shared use for modular expansion as required by the addition of subsequent expansion phases up to the maximum capacity of the light hydrocarbon gas for the process in the launch train as constructed and expanded in the one or more optional expansion phases to the required capacity.
 19. The method of claim 18 further comprising the following steps: d) constructing one or more expansion phases to the launch train to increase the capacity of the launch train as required to liquefy additional selected quantities of light hydrocarbon gas up to the selected maximum quantity of light hydrocarbon gas for the process, said expansion phases being capable of producing liquefied light hydrocarbon gas by use of the shared use facilities in the launch train as constructed and expanded in the one or more expansion phases up to the required capacity.
 20. The method of claim 18 wherein the shared use facilities include acid gas removal equipment.
 21. The method of claim 18 wherein the shared use facilities include mercury removal equipment.
 22. The method of claim 18 wherein the shared use facilities include dehydration equipment.
 23. The method of claim 18 wherein the shared use facilities include refrigerant compression equipment and cryogenic heat exchange equipment.
 24. The method of claim 18 wherein the shared use facilities include C³ ⁺ hydrocarbon removal facilities.
 25. The process of claim 1 wherein the shared use facilities include C³ ⁺ hydrocarbon removal facilities.
 26. The process of claim 7 wherein the shared use facilities include C³ ⁺ hydrocarbon removal facilities.
 27. The method of claim 12 wherein the shared use facilities include C³ ⁺ hydrocarbon removal facilities. 